RATHI Gear-Flex RGD Installation & Operation Manual Download Page 2

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GEAR-FLEX COUPLING

RE-OM-G-04/00-05/15

Page 2

TABLE OF CONTENTS

SR. No.

Topics

Page No

Product details

Notes

Technical Data

Marking Details

Installation

Start-Up and Operations

Failures - Causes and Remedies

Maintenance and Repair

Storage

Coupling Spare Components

Declaration : ATEX

Summary of Contents for Gear-Flex RGD

Page 1: ...INSTALLATION OPERATION MANUAL FOR TYPE RGD RGS RATHI TRANSPOWER PVT LTD Gaia Apex S No 33 2D Viman Nagar PUNE 411 014 INDIA ...

Page 2: ...TS SR No Topics Page No Product details 1 Notes 3 2 Technical Data 5 3 Marking Details 8 4 Installation 9 5 Start Up and Operations 14 6 Failures Causes and Remedies 16 7 Maintenance and Repair 18 8 Storage 18 9 Coupling Spare Components 19 10 Declaration ATEX 20 ...

Page 3: ...nel 1 2 SAFETY AND ADVICE INSTRUCTIONS Danger Danger of injury to persons Caution Damages on the machine possible Attention Pointing to important items Caution Hints concerning explosion protection 1 3 GENERAL INSTRUCTIONS OF DANGER Danger With assembly operation and maintenance of the coupling make sure that the entire drive train is protected against unintentional engagement Serious injuries can...

Page 4: ...ations The GEAR FLEX coupling described here corresponds to the technical status at the time of printing these assembly instructions 1 5 INTENDED USE OF THE COUPLING The intended use of the coupling is to connect input and output of a power transmission drive with each other in most cases these are two shafts For Stationary Application Additional equipment like brake drums torque limiter etc can b...

Page 5: ...2 45073 3200 52 180 346 278 135 235 274 123 165 8 131 1 39 50 650 62070 2900 72 195 389 314 153 254 306 141 183 8 186 2 53 55 880 84034 2650 72 215 425 344 168 279 334 158 203 8 247 3 83 60 1205 115069 2450 77 235 457 384 188 305 366 169 228 8 299 5 21 70 1823 174084 2150 92 280 527 451 221 356 425 196 266 9 473 11 80 2639 252006 1750 95 285 590 508 249 385 485 243 300 10 682 20 72 90 3037 290012 ...

Page 6: ... 57 180 200 346 266 135 235 274 276 123 131 00 50 650 62070 2900 72 77 195 220 389 301 153 254 306 309 141 148 00 55 880 84034 2650 72 77 215 240 425 341 168 279 334 334 158 173 00 60 1205 115069 2450 77 82 235 260 457 374 188 305 366 366 169 186 00 70 1823 174084 2150 92 102 280 300 527 439 221 356 425 425 196 218 80 2639 252006 1750 95 105 285 335 590 498 249 385 485 470 243 249 00 90 3037 29001...

Page 7: ...COUPLING RE OM G 04 00 05 15 Page 7 2 2 PRODUCT VARIANTS Coupling with Brake Drum Coupling with Brake Disc Coupling with Shear Pin Coupling with Spacer Coupling with Floating Shaft Coupling with Vertical Mounting ...

Page 8: ...FLEX COUPLING RE OM G 04 00 05 15 Page 8 3 MARKING DETAILS e g ATEX Punching RATHI GEAR FLEX 505 RGD 25 32 II 2GD 30 C 120ºC e g Standard Punching RATHI RGD 25 32 505 Bolts Marking of Grade 8 8 on bolt head ...

Page 9: ...these values the hub may break and the particles dispersed by the rotation may cause serious danger 1 Rathi couplings are supplied with pilot bore unless ordered for finish bore They should be bored to required finish bore sizes with reference of the outside diameter OD of hub Refer fig A 2 Clamp the hub puller hole side dia on lathe and true the hub O D Maintain concentricity of finish bore w r t...

Page 10: ...3 resp between shaft ends by using a spacer bar equal in thickness to the required gap G as shown in Fig 2 Deviation in standard DBSE is defined as axial misalignment end float For normal applications the shaft end should be flush with inner face of the hub In some special cases the shaft ends may protrude beyond the inner face of the hub or may remain inside if required The distance between two f...

Page 11: ...dial alignment with the help of straight edge resting squarely on both the hubs at 4 places 90 apart The deviation in the readings should not exceed the permissible initial parallel misalignment mentioned in table A Refer Fig 3 4 4 2 CHECKING ANGULAR ALIGNMENT Check the angular misalignment with the help of slip gauges by inserting in the gap at 4 places 90 apart The difference in max min gap will...

Page 12: ...cessity for shields guards varies with individual installations The owner or user must provide the required safety guards Safety guards or shields are not furnished by us with the couplings 4 6 PERMISSIBLE INITIAL INSTALLATION MISALIGNMENTS TABLE A TYPE RGD TYPE RGS ANGULAR ANGULAR COUPLING SIZE DEG GEAR MESH X mm PARALLEL RADIAL P mm AXAIL mm GAP G STD mm DEG GEAR MESH X mm AXIAL mm GAP G STD mm ...

Page 13: ... 0 6 3 1 2 4 15 1 6 0 8 3 1 6 4 20 2 1 3 2 4 25 2 4 1 2 5 2 4 5 30 2 8 1 4 0 5 5 2 8 0 25 5 35 3 2 1 7 6 3 2 6 40 3 6 2 6 3 6 8 45 4 2 1 8 4 8 50 4 4 2 6 8 4 4 9 55 4 8 2 9 1 8 4 8 0 5 9 60 5 2 3 2 8 5 2 9 5 70 6 3 7 9 6 11 80 6 8 4 2 10 6 8 13 90 7 6 4 8 2 13 7 6 1 15 100 0 75º 8 4 5 5 3 13 0 75º 8 4 1 5 16 Half Flexible Gear Couplings Type RGS cannot accommodate parallel misalignment Gap G in th...

Page 14: ...2 70 6 35 3 175 13 80 9 6 4 8 14 90 13 3 6 65 15 100 17 3 8 65 RECOMMENDED GREASE RATHI SPECIAL GREASE RSG EXXON MOBIL EP2 ESSO HMP BEACON 2 OR 3 SHELL δg 910 Kg m3 If the grease quantity filled is not in accordance with the specified quantity the coupling may become an explosion hazard 5 2 PROCEDURE BEFORE START UP Bolt tightening torques for the coupling and tightening torques for the foundation...

Page 15: ...50 265 10 55 265 11 60 265 12 70 396 13 80 334 14 90 653 15 100 653 If the coupling is to be used below ground in potentially explosive areas the coupling which is made of steel must be provided with a robust casing to avoid the risk of ignition from e g friction impact or friction sparks The depositing of heavy metal oxides rust on the coupling must be avoided by the casing or other suitable prec...

Page 16: ... as a fault requiring immediate remedy In case of fault the drive must be stopped at once The necessary measures for repair must be taken in accordance with the safety regulations Caution RATHI will not be bound by the terms of the guarantee or otherwise be responsible in cases of improper use of the coupling modifications carried out Without RATHI s agreement or use of spare parts not supplied by...

Page 17: ... peak load Use coupling with heat treatment on teeth 3 Noise during running No lubrication Refill the grease upto required limit 4 Heat Generation No lubrication Poor lubrication Refill the grease upto required limit Refer maintenance guidelines for lubrication frequency 5 Grease leakage Improper sealing Ensure proper sealing to avoid grease leakage 6 Loose hubs on shaft with sheared keys Torsiona...

Page 18: ...pling with new grease Maintenance checks a Check for vibration and noise b Check for leakage c Check for damages on gear teeth d Check for damages and deterioration of O ring e Check for deterioration of grease Checks mentioned above in Sr No a b can be made by observing from outside after comparing with condition under normal operation The other checks should be carried out every six months by di...

Page 19: ...D RGS COUPLING COMPONENTS SR NO TYPE PART NO COUPLING PARTS QTY 1 SLEEVE 1 2 HUB 1 3 BOLTS NUTS AND WASHERS 4 O RING 1 A RGD FLEXIBLE GEAR COUPLING HALF 5 GASKET 1 6 RIGID HUB 1 5 GASKET 1 B RGS RIGID GEAR COUPLING HALF 3 BOLTS NUTS AND WASHERS ONE FULL SET AS PER COUPLING SIZE ...

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